Brick, tile, or analogous article and the process of making same.



A. MALINOVSZKY. BRICK, TILE, 0R ANALOGOUS ARTICLE AND THE PROCESS OFMAKING SAME.

APPLICATION FILED APR. 19, 1910.

1,01 6,345. Patented Feb. 6, 1912.

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To all who 71bit may concern STATES PATENT OFFICE.

ANDR MALINovszKY, or TOLEDO, OHIO, ASSIGNOR, Br manor AND MESNE ASSIGN-.MnNTs, or O E-FOURT 'ro JOHN H. TAYLOR, OF,SCHENECTADY, NEW YORK, ANnrnnnn-ronn'rns TO' THE SANITARY BRICK COMPANY, or SGHENECTADY, NEW

than, A CORPORATION or NEW YORK.

nmcx, TILE, DBANALOGOUS ARTICLE AND THE rnoonss or MAKING sAJvrn.

Be it known that 1, ANDREW MALINOi T sznr, acitizen of the UnitedStates, and

resident of Toledo, in the county of Lucas and State of Ohio,haveinvented a certain new and usefulBrick, Tile, or Analogous Articleand the Process of Making Same; and I do hereby declare the followingtobe a full, clear, and exact description of the invention, such as willenableothers skilled in the art to which it appertains to make I and usethe same, reference being had to the accompanyin ,drawings, which form apart of this speci cation.

My invention relates to brick, tile, shingles, panels or the like,adapted for use in the construction of buildings, refrigerators,caskets, etc, but is not restricted to such uses as it may be used forany purpose for which it may be adapted or appropriate.

. The object of my invention is to produce a brick, shingle, tile or thelike which shall be of low cost, ornamental in-appearance, stron anddurable in construction, weatherprooi, and capable of resisting chemicalreactions, either acid or alkaline. In one form of my invention theresulting articles are capable of being worked with ordinary toolsalmost as easily as hard wood, and in such form is especially adaptedfor use as shingle's, some kinds of tile, and as insulating material forelectrical work; while in another itorm thereof the articles are highlyput one form only of the same is illustrated infthe accompanyingdrawings, which represent a brick.

in the making of my improved brick, tile ,or the like, ll preferablycombine the followa ing ingredients in substantially the proportionsnoted, but such proportions may be Specification of Letters Patent. IApplication filed April is,

g to be put.

Patented Feb. 6, 1912. 1910. Serial No. 556,345.

varied without departing from the spirit of the invention:

Silicious sand 73% Calcium oxide 5% Pegmatite 12% Magnesia silicate 6%Aluminumhydroxid 4% Toobtain the best results it ispreferable to finelycrush about 25% of the silicious sand used, or about 18% of the entiremass, so that it will pass through a sieye of not less than 140 mesh,and this is then mixed with the calcium oxid. The pegmatite and magnesiasilicate are then thoroughly calcined so as to expel all the water ofcrystallization therefrom. Unless this is completely done, thesubsequent heating or firing of the brick or other article will act toexpel the remaining moisture and cause a checking or possib e fracturingthereof. The crushing or reducing of a substantial portion of the sandto a powder prevents voids from occurring in the product. It may be saidthat the magnesia silicate used is in the form of serpentine rock, whilethe pegmatite is a finely crushed granite containing quart-z, mica andfeldspar. Pegmatite is used in preference to other varieties of graniteon account of its greater friability. It is to be understood, however,that the word pegmatite as used in'the claims is to be consideredbroadly as granite and not as a variety thereof.

A portion of the sand, the calcium oXid, pegmatite and magnesia silicatehaving been prepared as above stated, are placedv with the otheringredients and the whole thoroughly dry-mixed. Sufficient water is thenadded to form a heavy mortar-like mass which may be molded in any wellknown manner into the desired form. Without preliminary air-drying, themolded articles. are now ready for the operation of heating, baking orfiring, the degree of heat required varying within wide limitsincorrespondence with the desired appearance of the articles and the useto which they are for all kinds of electrical work and to take. theplace of porcelain, pressed fiber and the I other kinds of insulationnow commonly used in such work. If a hardened vitrified brick or otherartitile is desired it may be fired in a kiln for say 24 to 30 hours ata temperature Varying from 2220 to 2700 degrees Fahrenheit, or more,thehardness and completeness of the vitrification of the. article varying,of course, directly with the time of exposure and the temperature. Thehigher tem erature and .longer exposure named wil ordinarily harden andvitrify brick to such an extent as to adapt them for use in liningfurnaces, or the like, as above stated.

While it is preferable ordinarily to use all of the ingredientsmentioned above, either or both of the ingredients magnesia silicate andalumina may be omittedwithout materially affecting the use of theresulting article for certain purposes.

The purpose of alumina is to bind the particles of the mass together andto hold the impurities within the brick or other article instead ofallowing them to work down through the mass and appear on the under sidethereof in the form of crystals,

as is otherwise the case. In other words, the use of alumina widens thezone of vitrifica-- tion without permitting a fusion of the article..Where brick or the like are piled one on top of another within a kilnwith only sand sprinkled between them, as is customarily done, and thealumina is omitted therefrom, the expelled impurities will cause a rigidcementing or adhering together of the adjoining articles, thusnecessitating a breaking of e same apart. If the articles, however, fromwhich they alumina is omitted are not burned immediately after molding,but are exposed to the air for two or three days, or for a suflicientlength of time for the carbonic acid in the a1r to act thereon to effectthe necessary hardening or binding action, they may be then burnedwithout the expulsion of the lmpurities. Or, if, instead of air dryingthe articles, they are steamed for 8 or 10 hours,

- or for a suitable length of time for them to become sufficientlyhardened to retain theirl integrity, they may then be burned in a kilnwithout expelling the impurities. When making articles in slab or thinform, as

for instance one foot square and one-half inch thick, it is preferableto first air or steam dry the same before burning, as they can be thenmore easily' handled without danger of breaking or bending:

The use of magnesia silicate or serpentine rock in the compositionrenders it tough and more pliable when hot and also prevents a crackingor checking of the same different temperatures at the same time,

should contain magnesia silicate. The inclusion of magnesia silicatealso prevents an article from cracking when placed hot in a coolingwater and enables it to stand a higher heat, while the exclusion thereofrenders an article brittle and causes it to shrink quite materially fromits original size. Ifalumina is omitted its proportion in thecomposition is preferably added to the pegmatite; if magnesia silicateis omitted its proportion is preferably added to the sand, and in caseboth'of said ingredients are omitted the relative proportions of theother ingredients preferably remain about the same. A

It is found that the presence of pegmatite in the composition, eitherwith silica and calcium oxid alone or with all of the other ingredientsmentioned is veryimportant. Silica under the conditions existing hereinis wholly infusible as it has no plasticity. It alone, therefore has nobinding power.

The addition of calcium oxid, however,.

form composed of silica and calcium oxid alone is not very durable. Theatmosphere easily disintegrates it so that great care must be taken toprevent the air from striking under the brick within the kiln, asotherwise crumbling may. result. To overcome this difficulty and toproduce a better, stronger and commercially practical article of thisnature, pegmatite is added to the silica and calcium oxid, if suchingredients are used alone, or to the compound of which such ingredientsform a' part,-as it is found by experiments that the presence ofpegmatite'thereinproduces a brick or other article that will endure avery high fire resistance and will, because of its perfectvitrification, be proof against'any effect from atmosphere. In this waya first class enamel-faced brick can be produced, which would not bepossible if the pegmatite was omitted from the other ingredients. Thecalcium oxid serves as a cement and also as a flux to'the pegmatite, sothat during burning a quick reaction takes place between the calciumoxid and but, in actual practice, both the relatively. soft and workablearticles and the hard vitrified ones have been successfully producedwith the mixture stated.

- Having thus described my invention, what I claim as new, and desire tosecure by Letters Patent, is,

1. An article of the class described, composed of a compound obtained byheating together silica calcium oxid and pegmatite.

2. An article of the class described, com posed of a compound obtainedby heating together silicious sand, calcium oxid and pegmatite, the sandforming a major portion of the entire mass and a substantial portion ofthe same being finely crushed.

3. An article of the class described, composed of a compound obtained byheating together silicious sand, calcium. oxid, calcined magnesiasilicate and. pegmatite, the sand forming at least 60% and thepegmatit'e at least 10% of the entire mass.

i. An article of the class described, composed of a compound obtained byheating together silicious sand, calcium oxid, pegmatite, and calcinedmagnesia silicate, the

sand constituting a major portion of the compound. V

5. An article of the class described, composed of a compound obtained byheating together silicious sand, calcium oxid, calcined and groundserpentine rock, alumina and pegmatite, the sand forming at. least 60%of the entire mass and the serpentine rock in suficient quantity to forma binder.

6. An article of the class described, com-- posed ofa compound obtainedby heating together silicious sand, calcium oxid, pegmatiteand magnesiasilicate in substantially the proportion stated, a substantial portionof the sand being finely ground and the magnesia silicate beingcalcined.

7. An article of the class described, composed of a compound obtained byheating together silicious sand, calcium-oxid, pegs Inatite, magnesiasilicate and alumina, in substantially the proportions stated.

8. An article of the class described, composed of a compound obtained byheating together silicious sand, 55 to 90%, calcium oxid, 2 to 7%,calcinedmagnesia silicate 4 to 10%, alumina 2 to 6% and pegmatite 10 to20%.

9. The process of making articles of the class described, consisting inmixing silicious sand, calcium oxid and pegmatite, a major portion ofthe entire mass being sand,

Wetting the mixture to a molding consistency, molding the articles, andheating them to a temperature above that required to evaporate themoisture therefrom.

10. The process of making articles of the class described, consisting inmixing silicious sand, 55 'to 90%, calcium oxid, 2 to 7%, and calcinedpegmatite, 8 to 20%, a substantial portion of the sand being finelyground, wetting the mixture to a molding consistency, molding thearticles, and heating them to a temperature above that required toevaporate the moisture therefrom.

11. The process of making articles of the class described, consisting inmixing silicious sand, calcium oxid, calcined pegmatite and calcinedmagnesia silicate, a major portionof the entire mass being sand and asubstantial portion of the sand being finely ground, wetting the mixtureto a molding consistency, molding the articles, and heating them toatemperature above that required to evaporate the moisture therefrom.

12. The process of making articles of the class described, consisting inmixing silicious sand, calcium oxid, calcined pegmatite, calcinedmagnesia silicate, and alumina in substantially the proportions stated,a substantial portion of the sand be ing finely ground, wetting themixture to a molding consistency, molding the articles, and heating themto a temperature above that required to evaporate the moisturetherefrom.

13. The process of making articles of the class described, consisting inmixing sili cious sand, calcium 'oxid and calcined pegmatite, wettingthe mixture to a molding consistency, molding the articles, and burning.them to efiect vitrification. I 14. The process of making articles ofthe class described, consisting in mixing silicious sand, calcium oxid,calcined pegmatite and calcined magnesia silicate in substantially theproportions stated, wetting the mixture to a molding consistency,molding the articles, and burning them to effect vitrification.

15. The process of making articles of the "class described, consistingin mixing silicious sand, calcium oxid, calcined pegmatite, calcinedmagnesia silicate and alumina substantially as described, wetting themixture to a molding consistency, molding the articles, and burning themto effect vitrification.

16. The process of making articles of the class described, consisting inmixing silicious sand, calcium oxid and pegmatite, wetting the mixtureto a molding consistency, molding the articles, drying them, and thenburning to efiect vitrification.

17. The process of making articles of the class described, consisting inmixing sili cious sand, calcium oxid, pegmatite and magnesia silicate,Wetting the mixture to a mixture to a molding consistency, moldingmolding consistency, molding the articles, the articles in thin form,drying them, and 10 drying them and then burning to effect vitthenburning to efiect vitrification.

rification. v v r 18. The process of making articles of the ANDREWMALINOVSZKY' class described, consisting in mixing sili- I Witnesses:

cious sand, calcium 'oxid, calcined pegmatite, GE L. COOPER,

magnesia silicate and alumina, wetting the JOHN H. TAYLOR.

